MARSHALL MIX DESIGN

1.0 INTRODUCTION
The main purpose of the design process is to determine the optimum bitumen content
(OBC) of each asphaltic mixture. Before any asphalt mixes can be placed and laid on the road,
the aggregate and the binder types are generally screened for quality and requirement.
Approximately 15 samples are required Optimum Asphalt Content (OAC). The aggregates blend
that will be used for mixtures preparation must fall within the specification requirements.
Properties such as density and bulk specific gravity of aggregate and bitumen used for each
mixture must be determined earlier before carrying out Marshall Test. By using the Asphalt
Institute Method, the Optimum Asphalt Content are determined from the individual plots of bulk
density, voids in total mix and stability versus percent asphalt content. The average of the 3
OAC values is taken for further sample preparation and analysis.

2.0 THEORY
The mix design determines the optimum bitumen content. There are many methods
available for mix design which varies in the size of the test specimen, compaction and other test
specifications. Marshall Method of mix design is the most popular one. The Marshall Stability
and flow test provides the performance prediction measure for the Marshall Mix design method.
Load is applied to the specimen till failure, and the maximum load is designated as stability.
During the loading, an attached dial gauge measures the specimens plastic flow (deformation)
due to the loading.
The amount of binder to be added to a bituminous mixture cannot be too excessive or too
little. The principle of designing the optimum amount of binder content is to include sufficient
amount of binder so that the aggregates are fully coated with bitumen and the voids within the
bituminous material are sealed up. As such, the durability of the bituminous pavement can be
enhanced by the impermeability achieved. Moreover, a minimum amount of binder is essential
to prevent the aggregates from being pulled out by the abrasive actions of moving vehicles on
the carriageway. However, the binder content cannot be too high because it would result in the
instability of the bituminous pavement. In essence, the resistance to deformation of bituminous
pavement under traffic load is reduced by the inclusion of excessive binder content.

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MARSHALL MIX DESIGN

3.0 OBJECIVES
(i)

To prepare standard specimens of asphalt concrete for the determination of the optimum
asphalt content based upon ASTM D 1559, Resistance to Plastic Flow of Bituminous

(ii)

Mixtures Using Marshall Apparatus.

To determine the combination of bitumen and aggregate that will give durable road
surfacing.

4.0 EQUIPMENT AND MATERIAL

(i)
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
(viii)

Marshall compactor
Mixer
Water Bath
Oven
Thermometer
Marshall Compression Machine
Marshall Mould
Sieve Shaker

5.0 PROCEDURE
In the Marshall Test method of mix design, three compacted samples are prepared for each
binder content. At least four binder contents are to be tested to get the optimum binder content.
All the compacted specimens are subjected to the following test:
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MARSHALL MIX DESIGN

a)
b)
c)
d)

Bulk specific gravity determination test (ASTM D 2726)

Theoretical Maximum Specific Gravity (AASHTO T 209)
Marshall Stability and Flow Test (ASTM D 1559)
Density and voids analysis (ASTM D 2726)

5.1 Preparation of the Test Specimens

(i)

The aggregate (about 1200g), graded according to the ASTM standard are over dried

(ii)

at 170 180 C (not more than 280 C).

The required quantity of asphalt is weighted and heated to a minimum temperature of

(iii)

about 135 C (maximum 160 C 5 C).

The thoroughly cleaned mould is heated on a hot plate or in an oven to a temperature
of about 135 150 C. The mould is 101.6 mm diameter by 76.2 mm high and

(iv)

provided with a base plate and extension collar.

A crater is formed in the aggregate, the binder poured in and mixing carried out until all
the aggregate is coated. The mixing temperature shall be within the limit set for the

(v)

binder temperature.
A piece of filter paper is fitted in the bottom of the mould and the whole mix poured in
three layers. The mix is then vigorously trowel 15 times round the perimeter and 10

(vi)
(vii)

times in the centre leaving a slightly rounded surface.

The mould is placed on the Marshall Compactor and given 75 blows.
After compaction, the base plate is removed and the same blows are compacted to the

(viii)

bottom of the sample that has been turned around.

The specimen is then carefully removed from the mould and then marked.

5.2 Bulk density gravity determination test (ASTM D2726)

5.2.1

Introduction
Bulk specific gravity of compacted Hot Mix Asphalt (HMA) specimens, G mb,is
theratio of the weight in air of a unit volume of a compacted specimen of HMA
(including permeable voids) at a standard temperature to the weight of an equal
volume of water at a stated temperature. The bulk specific gravity can be
calculated by using the following equation;

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MARSHALL MIX DESIGN

Bulk Specific Gravity, Gmm =

A
)
BC

Where:
A = mass of specimen in air (g)
B = saturated surface dry (SSD) mass (g)
C = mass of specimen in water (g)

5.2.2

Apparatus
Apparatus that used in this test are:
(i)
(ii)

5.2.3

Balance; and
Water Bath.

Procedure
(i)

The specimen is cooled to a room temperature at 25 1 C and the dry

(ii)

mass is recorded as A.
The specimen is immersed in a 25 1 C water bath and saturated at 4 1

(iii)

minute.
The specimen is then, placed in a basket and its mass is determined to

(iv)

nearest 0.1 g while immersed in water at 25 1 C.(C)

The immersed saturated specimen is removed from the water bath and
damp dried with a damp absorbent cloth as quickly as possible. The
specimen is then weighted, (B). Any water that seeps from the specimen
during the weighing operation is considered as part of saturated specimens.

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MARSHALL MIX DESIGN

5.3 Theoretical Maximum Specific Gravity (AASHTO T 209)

5.3.1

Introduction
Theoretical maximum specific gravity, Gmm, is the ratio of the weight in air of
the a unit volume of uncompacted bituminous paving mixture at a stated
temperature to the weight of an egual amount of water at a stated temperature. It
is also called Rice Specific Gravity. The theoretical maximum specific gravity can
be calculated by using the following equation;

Theoretical Maximum Specific Gravity , Gmm=

A
)
A +BC

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MARSHALL MIX DESIGN

Where:
A= sample mass in air (g)
B= mass of container filled with water (g)
C= mass of container and sample filled with water (g)

5.3.2

Apparatus
Apparatus that used in this test are:
(i)
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
(viii)
(ix)

5.3.3

Vacuum Container;
Balances;
Vacuum lid;
Vacuum pump or water aspirator;
Manometer or vacuum gauge;
Thermometer;
Water bath;
Bleeder valve; and
Timer.

Procedure
(i)

Separate the particles of the sample, taking care not to fracture the mineral
particles, so that the particles of the fine aggregate portion are not large
than 6.3mm (1/4in). If the mixture is not sufficiently soft to be separated
manually, place it in a large flat pan and warm in an oven only until it is

(ii)
(iii)
(iv)
(v)
(vi)

pliable enough to separation.

Cool the sample to room temperature.
Determine and record the mass of the flask, including the cover.
Place the sample in the flask.
Determine and record the mass of the flask, cover, and the sample.
Add sufficient water at approximately 25 1C to cover the sample by

(vii)

25mm.
Place the lid on the flask and attach the vacuum line. To ensure a proper

(viii)

seal between the flask and lid, wet the O-ring or use a petroleum gel.
Remove entrapped air by subjecting the contents to a partial vacuum of 3.7
0.3 kPa residual pressures for 15 2 minutes.

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MARSHALL MIX DESIGN

(ix)

Agitate the container and contents, either continuously by mechanical

device or manually by vigorous shaking, at 2-minute interval. This agitation

(x)

facilitates the removal of air.

Slowly open the release valve, turn off the vacuum pump and remove the

(xi)

lid.
Suspend and immerse the flask and contents in water at 25 1C for 10 1

(xii)
(xiii)

minutes. The holder shall be immersed sufficiently to cover it and the flask.
Determined and record the submerged weight of the flask and contents.
Empty and re-submerge the flask following step (xi) to determined the
submerged weight of the flask.

5.4 Marshall stability and flow test (ASTMD1559)

5.4.1

Introduction
The most widely used method of asphalt mix design is the Marshall method
developed by the U.S. Corps of Engineers. The Marshall Flow and stability test
provides the performance prediction measure for the Marshall Mix design
method. The stability portion of the test measure the maximum load supported by
the test specimen at a loading rate of 51mm/min. Stability and flow, together with
density, voids and percentage of voids filled with binder are determined at
varying binder contents to determine an optimum for stability, durability, flexibility,
fatigue resistance, etc.
The mechanism of failure in the Marshall Test apparatus is complex but it is
essentially a type of unconfined compression test. This being so, it can only have
limited correlation with deformation in a pavement where the material is confined
by the tire, the base and the surrounding surfacing. Wheel tracking tests have
shown that resistance to plastic flow increases with reducing binder content
whereas Marshall Stability decreases. Improvement on the assessment, based
on stability, is possible by considering flow and most agencies (e.g. Asphalt
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MARSHALL MIX DESIGN

Institute, Malaysias JKR) set minimum for stability and maximum for flow for
various purposes (roads, airports, etc)
In addition to binder content, stability and flow being the prime variables in
the performance of an asphalt sample, the type of binder, grading of aggregate,
the particle shape, geological nature of parent rock (most importantly; porosity),
degree of compaction, etc. also play an importance role.

5.4.2

Apparatus
Apparatus that used in this test are:

(i)
Marshall Stability and Flow Machine;
(ii)
Water bath; and
(iii)
Rubber glove.
5.4.3 Procedures
The dimension and specifications of the Marshall apparatus are explained in
ASTM D 1559. The diameter of the specimen is 101.6 mm and nominal thickness
is 63.5 mm.
(i)

Three specimens, were prepared according to the Standard, are immersed

(ii)

in a water bath for 30 to 40 minutes or in an oven for 2 hours at 60 1.0 C.

The testing heads and guide rods are thoroughly cleaned; guide rods

(iii)

lubricated and head maintained at a temperature between 21.1 and 37.8C.

A specimen is removed from the water bath or oven, placed in the lower jaw
and the upper jaw placed in position. The complete assembly is then placed
in the Marshall Stability and flow machine and the flow meter adjusted to

(iv)

zero.
The load is applied to the specimen at a constant strain rate of 50.8
mm/min until the maximum load is reached. The maximum force and flow at
that force are read and recorded. The maximum time thats allowed
between removal of the specimens from the water bath and maximum load
is 30 second.

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MARSHALL MIX DESIGN

5.5 Density and Voids Analysis (ASTM D 2726)

5.5.1

Bulk Density

The bulk density of the specimen is simply determined by weighing in air and
water.

Bulk Density, d = Gmb x w

Bulk Specific Gravity, Gmb =

A
)
BC

Where:
d

= Bulk density (g/ cm)

Gmb

= Bulk Specific Gravity of the mix

= density of water (1 g/ cm)

= mass of specimen in air (g)

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MARSHALL MIX DESIGN

5.5.2

= saturated surface dry (SSD) mass (g)

= mass of specimen in water (g)

Percentage of Air Voids (%AV)

The percentage of air voids in the mix is determined by firstly calculating the
maximum theoretical density TMD (zero voids) and then expressing the
difference between it and the actual bulk density d as a percentage of total
volume.

AV (%) =

Gmb
(1 Gmm
) x 100

Where:
Gmb = Bulk Specific Gravity of the mix
Gmm = maximum theoretica

5.5.3

Theoretical Maximum Specific Gravity

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MARSHALL MIX DESIGN

(
Gmm =

([

100
)
100Pb
Pb
+
Gse
Gb

] [ ])

Or Max specific gravity test

(AASHTOT209)

Where:

[ [(

(
Gse =

5.5.4

100Pb

)] ( )

100
Pb

Gmm
Gb

Gmm

= maximum theoretical Specific Gravity of the mix

Pb

= asphalt content, percent by the weight of the mix

Gse

= effective specific gravity of the mix

Gb

= Specific Gravity of asphalt cement

Voids in the Mineral Aggregate (VMA)

The volume of void in mineral aggregate VMA is an important factor for the
mixture design.

VMA = 100 (1 [

Gmb (1Ps)
])
Gsb

Where:
Gmb

= Bulk Specific Gravity of the mix

Ps

= asphalt content, percent by weight of the mix

Gsb

= bulk specific gravity of the aggregate

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MARSHALL MIX DESIGN

5.5.5

Voids filled with Asphalt (VFA)

VFA =

x 100
( VMAAV
VMA )

Where:
VFA

= voids filled with asphalt

VMA

= void in mineral aggregate

AV

= the percentage of air voids

6.0 ANALYSIS OF RESULT

7.1 Gradation

The Aggregate Grading

Sieve Size
20.00mm
14.00mm
10.00mm
5.00mm
3.35mm
1.18mm
0.425mm
0.150mm
0.075mm
pan

Control
Point
100
90-100
78-86
50-62
40-54
18-34
12-24
6-14
4-8

% Passing

% Retained

Weight (g)

100.0
87.5
79.0
58.0
50.0
24.0
20.0
11.5
6.0
0.0

0.0
12.5
8.5
21.0
8.0
26.0
4.0
8.5
5.5
6.0

0.0
140.6
95.6
236.25
90.0
292.5
45.0
95.625
61.875
67.5

Accumulated
Weight (g)
0.0
140.6
236.2
472.45
562.45
854.95
899.95
995.575
1057.45
1125.0

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MARSHALL MIX DESIGN

Total Weight of Aggregates and Filler
Total Weight of Aggregates

1125.0 g

Filler (2%)
Weight of Aggregates + Filler

22.5 g
1147.5 g

Percentage of Binder
% Binder
5.0
5.5
6.0
6.5

Weight of binder (g)

60.4
66.8
73.2
78.1

Total weight (g)

1208
1214
1221
1226

7.2 Aggregate Specific Gravity

Where:
A= sample mass in dry (burn in oven) (g)
B= sample mass that had been dry at the surface of aggregate in air (g)
C= sample mass in water (g)
Aggregate size 10mm;
SAMPLE
A
B
C
SGAgg.
AVERAGE

1
711.6
833.0
442.5
1.822

2
779.7
783.0
484.5
2.612
2.217

Aggregate size 14mm;

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MARSHALL MIX DESIGN

SAMPLE
A
B
C
SGAgg.
AVERAGE

1
860.5
864.0
533.0
2.600

2
831.7
835.0
516.0
2.607
2.604

Therefore, take aggregate size 14mm as specific gravity; SGAgg = 2.604

7.3 Bulk Specific Gravity, Gmb.

Where;
A= sample mass in air (g)
B= sample mass that had been dry at the surface of bitumen in air (g)
C= sample mass in water (g)
BITUMEN
CONTENT

5.0

5.5

6.0

6.5

(%)
NO.
SAMPLE
A
B

1
1164.5
1175.5

2
1196.5
1198.5

1
1199.5
1200.

2
1179.0
1182.5

1
1160.0
1166.5

2
1104.5
1105.0

1
1184.0
1186.5

2
1187.5
1292.0

C
Gmb

650.5
2.218

689.0
2.348

0
693.5
2.368

674.0
2.319

660.0
2.290

639.0
2.370

675.0
2.315

679.5
2.317

AVERAGE

2.283

2.344

2.330

2.316

7.4 Theoretical Maximum Specific Gravity,Gmm.

Where;
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MARSHALL MIX DESIGN

A= sample mass in air (g)
B= mass of container filled with water (g)
C= mass of container and sample filled with water (g)

BITUMEN

5.0

5.5

6.0

6.5

CONTENT (%)
A
B
C
Gmm

1151.30
1380.00
2054.50
2.415

1201.90
1380.00
2084.00
2.414

1200.40
1380.00
2080.00
2.399

1165.40
1380.00
2058.50
2.394

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MARSHALL MIX DESIGN

7.5 Marshall Test Result
SGBit. = 1.020
SGAgg.= 2.604
% Bit.
Spec.
No.

% Bit.
Spec.
No.

% Bit.
by
weight
of Agg.

% Bit.
by
weight
of Mix
5.0
5.0
5.0
5.5
5.5
5.5
6.0
6.0
6.0
6.5
6.5
6.5

AVG.
AVG.
AVG.
AVG.

Weight (gram)
Saturat
In
In
ed
Air
Water
Surfac
e
Dry
c

1175.5
1198.5

1164.5
1196.5

650.5
689.0

1200.0
1182.5

1199.5
1179.0

693.5
674.0

1166.5
1105.0

1160.0
1104.5

660.0
639.0

1186.5
1192.0

1184.0
1187.5

675.0
679.5

Bulk
Vol.
cc.

Spec. Grav.
Bulk
Max.
Theor.
(Gmb)

(Gmm)

c-e

d
f

525.0
509.5
517.25
506.5
508.5
507.5
506.5
466.0
486.25
511.5
512.5
512.0

2.218
2.348
2.283
2.368
2.319
2.344
2.290
2.370
2.330
2.315
2.317
2.316

Volume-% total
Bit.
Agg.
Voids

Agg.

Voids (%)
Filled
Total
(Bit.)
Mix

(VMA)
i

bg
SGbit .

(100b)g
SGagg. 100-i-j

(VTM)

100-j

100(i/l)

100100(g/h)

2.415

11.191

83.289

5.520

16.711

66.968

5.466

2.414

12.639

85.065

2.296

14.935

84.627

2.900

2.399

13.706

84.109

2.185

15.891

86.250

2.876

2.394

14.759

83.159

2.082

16.841

87.637

3.258

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MARSHALL MIX DESIGN

% Bit.
Spec.
No.
a
% Bit. by
weight
of Agg.

AVG.
AVG.
AVG.
AVG.

% Bit.
Spec.
No.
b
% Bit.
by
weigh
t
of Mix
5.0
5.0
5.5
5.5
6.0
6.0
6.5

Stability

Flow (mm)

stiffness
s
q/r

Meas.

Correlation

o
Correlatio
n ratio

q
Pxo

1.000
1.000

12300
11050

1.000
1.000

12560
11000

1.000
1.000

13650
12500

1.000
1.000

10870
1234

12300
11050
11670.5
12560
11000
11780
13650
12500
13070.5
10870
12340
11600.5

3.270
3.290
3.280
3.560
3.770
3.665
4.400
4.180
4.290
4.500
4.780
4.640

6.5

355.95
321.42
304.78
250.11

From the graph, OBC = (a + b + c + d)/4 = e

= (5.79 + 5.82 + 5.28 + 5.29)/4
= 5.545

7.0 SAMPLE CALCULATION

For 6.5% bitumen content.

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MARSHALL MIX DESIGN

7.1 Aggregate Specific Gravity
Aggregate size 10mm,
Aggregate Specific Gravity, SG Agg.

A
BC

711.6
833.0442.5

711.6
833.0442.5

= 1.822
So, take average of Aggregate Specific Gravity, SG Agg. = 2.217

Aggregate size 14mm,

Aggregate Specific Gravity, SG Agg.

A
BC

860.5
864.0533.0

=2.600

So, take average of Aggregate Specific Gravity, SG Agg. = 2.604

Then, take the highest of Aggregate Specific Gravity = 2.604 (from Agg. size 14mm)

7.2 Bulk Specific Gravity, Gmb.

Bulk Specific Gravity, Gmb

A
BC

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MARSHALL MIX DESIGN

1184
1186.5675.0

= 2.315
And, take the average for sample 6.5 % = 2.316
7.3 Theoretical Maximum Specific Gravity, Gmm.
Theoretical Maximum Specific Gravity, Gmm =

A
A+ BC
1165.4
1165.4 +13802058.5

= 2.394

7.4 Percentage of Air Voids, (%AV) @ VTM.

VTM

= (1 -

G mb
G mm ) 100

= (1

2.316
2.394 ) 100

= 3.25 8

7.5 Void inMineral Aggregate, VMA

VMA = 100(1 G mb )

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MARSHALL MIX DESIGN

= 100(1

2.316 (10.065)
)
2.604

=16.841
7.6 Void filled with Asphalt, VFA

VFA

= 100(

VMA AV

VMA

= 87.637

7.7 Stiffness,S
From the experiment, Flow
Stability

Stiffness =

= 4.640mm
= 1160.5

stability
flow
1160.5
4.640

= 250.11

Then, prepare the following plots:

1)
2)
3)
4)
5)

Asphalt Content versus density (or unit weight)

Asphalt content versus Marshall Stability
Asphalt content versus air voids (or VTM)
Asphalt content versus VMA
Asphalt content versus VFA

From the graph, OBC = (a + b + c + d)/4 = e

= (5.79 + 5.82 + 5.28 + 5.29)/4

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MARSHALL MIX DESIGN

= 5.545

Compare parameters with JKR/SPJ/2008-S4 Specifications, design is satisfactory.

8.0 GRAPH MARSHALL PROPERTIES

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MARSHALL MIX DESIGN

Density vs Bitumen Content

Stability vs
Bitumen Content

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MARSHALL MIX DESIGN

VTM (%) vs Bitumen Content

VFA (%) vs Bitumen Content

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MARSHALL MIX DESIGN

VMA (%) vs Bitumen Content (%)

18
17
16
VMA (%) 15
14
13
4.8

5.2

5.4

5.6

5.8

6.2

6.4

6.6

Bitumen Content (%)

VMA (%) vs Bitumen Content (%)

Flow (mm) vs Bitumen Content (%)

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MARSHALL MIX DESIGN

Stiffness vs Bitumen Content (%)

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MARSHALL MIX DESIGN

9.0 DISCUSSION
From Marshall Mix design laboratory test, data and result were found based on
percentages sample binder such as 5.0%, 5.5%, 6.0% and 6.5%. The aggregate were
sieve exactly according the size were state in pavement manual laboratory. The sieve
was doing in properly sieve to prevent the wrong size. From the sieving three simple
were prepaid for each percentages of binder but only two simple were used as Marshall
Mix Design. The other one was used as simple to find the aggregate basic evaluation.
In Marshall Method were used Marshall Hammer, the Marshall Stability and flow
apparatus which is are the biggest differentiate aspects. Both method are easily to get to
the high and low temperature. The aggregate, were put in oven about 6 8 hour to dry it
before start the process of compaction. This is to ensure the aggregate are always in
dry. The aggregate, cement and asphalt (based on group percentages were given by
lecturer) were mix together in the kitchen at temperature 160 oC. Number of blows is
depending upon anticipated traffic loading such as 35, 50 or 75, but in this test was used
in 75 blows.
The Marshall sample is weighted to get the dry air mass and surface dry mass. The
basket was placed with the Marshall sample not touch below the water level and the
sample is wiped with towel before weighed to ensure get the surface dry mass. The
passing values of stability and flow depend upon the mix class being evaluated.
The total weight filler and aggregate is 1147.5g. For aggregate specific gravity we
were used aggregate size 14mm which is in the highest average 2.604 and the specific
gravity of bitumen is 1.020 were used in this laboratory test.
In this test each group were used their own percentages of binder. From calculation,
the 6.5% of binder, we get the average for bulk specific gravity is 2.316%. The rice
specific gravity is 2.394%, Air Voids is 3.258%, Void in the Mineral Aggregate (VMA) is
16.841%, and Void filled with asphalt (VFA) is 87.637%. From the experiment the flow
were got is 4.640mm, the stability is 1160.5 and the stiffness is 250.11mm.
On graph below we can get the different value compare with value of calculation.
This is because value point at graph are did not show the exactly shape of graph as

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MARSHALL MIX DESIGN

shown in graph below. Based on graph, the new value of density is 2.312, stability is
118000, Air Void is 3.25%, Void filled with asphalt (VFA) is 80%, Void in the Mineral
Aggregate (VMA) is 17%, Flow is 4.62 mm and stiffness is 252. From calculation of
graph OBC were get the value 5.545 All the value were compare with Specification for
Roadworks (JKR/SPJ/2008-S4: Flexible Pavement), Published by JKR Malaysia and
show that the design is satisfactory.

10.0

CONCLUSION
From the study of compactive effort and mix design the mix design criteria
recommended, the asphalt content that is too high. This is justification for use of a
modified mix design criteria that produces lower asphalt content. Comparison of bulk
densities produced during mix design and those from recompacting material from in
service pavements indicates that higher constructed density is achievable. A higher
compactive effort during construction would produce both higher and more uniform
density. So, base on our final results gained from the tests we can conclude that the
HMA design is capable to be used as the road pavement material because of the VMA
value we get from all the tests are adequate. The concepts are expected to give reliable
performance as well relative economy in construction. These can be validated further by
implementing in actual highway construction.

11.0

REFERENCES

(i)
(ii)
(iii)

Marshall Mix Design Laboratory Manual, UiTM Shah Alam

Lecturers note ECG 524, Chapter 3.0, Asphaltic Concrete Pavement Construction
http://www.cdeep.iitb.ac.in/nptel/Civil%20Engineering/Transportation%20Engg%20I/26-

(iv)

Ltexhtml/nptel_ceTEI_L26.pdf
http://www.engineeringcivil.com/what-is-the-optimum-binder-content-in-bituminouspavement.html

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